Pipelayer machine having hoisting system with pivotable fairlead

ABSTRACT

A machine includes a frame, ground-engaging elements coupled to the frame, and a hoisting system having a sideboom and a fairlead. The hoisting system also includes a hook pulley block and a hoisting cable extending through the fairlead and the hook pulley block and held in tension such that the hoisting cable couples pivoting of the fairlead to pivoting of the sideboom. The pivotable fairlead may be instrumented with position, cable loading, and cable feed sensors.

TECHNICAL FIELD

The present disclosure relates generally to a machine equipped with asideboom and fairlead for guiding a hoisting cable to and from thesideboom, and more particularly to such a machine where the fairlead ispivotable.

BACKGROUND

Pipelayers are specialized machines used to suspend and place pipelinesin a prepared trench or the like. A typical pipelayer includes a loadmanipulating boom that projects outwardly from the side of the machinein a direction generally perpendicular to a forward travel direction. Itis common for a cable and rigging system to be provided for manipulatingthe position of the boom, as well as a load suspended by the boomadjacent to or within a trench. It is also typical for pipelayers tooperate in teams with a group of the machines operating in a coordinatedfashion, to each support a different section of pipe as the pipe isgradually placed into a trench. In some instances the pipe sections arewelded together as they are suspended by the pipelayer machines.Pipelayer teams often require precise and concerted efforts not only forsuccessful placement but also to optimize speed and efficiency andprotect operators and ground crew personnel.

Due to the nature of pipeline placement and support of pipe sections outto the side of the machine, there can be challenges to stably supportingthe suspended load without risking tipping the machine. These challengescan be particularly acute in poor underfoot conditions, as well as steepterrain. To enhance stability most pipelayer machines are equipped witha counterweight positioned opposite the sideboom, and which can beadjusted to compensate for adjustments in the height and positioning ofa suspended load. One example pipelayer machine is known from U.S. Pat.No. 8,783,477 to Camacho et al. It will be appreciated that asignificant degree of operator skill can be required to control thespeed and travel direction of a pipelayer machine while also monitoringand adjusting the suspension height of the load and positioning of thesupporting sideboom. The availability of skilled operators, as well asground crew, at worksites that are often remote has long challenged theindustry. For these and other reasons, continued advancements andimprovements to develop and exploit technological solutions in thepipelayer field are desirable.

SUMMARY OF THE INVENTION

In one aspect, a fairlead for a hoisting system in a ground-engagingmachine includes a fairlead base for coupling to a frame of theground-engaging machine, a fairlead boom, and a pivot joint pivotablycoupling the fairlead boom to the fairlead base. The fairlead furtherincludes a plurality of feed pullies mounted to the fairlead boom forfeeding a hoisting cable through the fairlead between a winch assemblyand a sideboom in the ground-engaging machine. The fairlead furtherincludes instrumentation circuitry including a wiring harness structuredfor electrically connecting to hoisting control circuitry onboard theground-engaging machine.

In another aspect, a hoisting system for a ground-engaging machineincludes a winch assembly, a sideboom, and a fairlead for feeding ahoisting cable between the winch assembly and the sideboom. The fairleadincludes a fairlead base structured for coupling to a frame of theground-engaging machine, a fairlead boom, and a pivot joint pivotablycoupling the fairlead boom to the fairlead base. The hoisting systemfurther includes a control system having instrumentation circuitryresident on the fairlead and including a wiring harness for electricallyconnecting to hoisting control circuitry onboard the ground-engagingmachine.

In still another aspect, a method of operating a ground-engaging machineincludes producing a fairlead monitoring signal indicative of anorientation of a fairlead in a hoisting system of the ground-engagingmachine. The fairlead is supported upon a frame of the ground-engagingmachine and pivotable about a fairlead pivot axis relative to the frame.The method further includes producing a load monitoring signalindicative of a load on a hoisting cable guided by the fairlead to andfrom a sideboom pivotable about a sideboom pivot axis relative to theframe, and outputting an overload alert based on the frame monitoringsignal and the load monitoring signal.

In still another aspect, a machine includes a frame having a front frameend and a back frame end, and ground-engaging elements coupled to theframe. The machine further includes an operator station coupled to theframe, and a hoisting system including a sideboom, a winch assembly, anda fairlead, coupled to the frame. The sideboom is pivotable about asideboom pivot axis to vary an orientation of the sideboom between araised sideboom position, and a lowered sideboom position at which thesideboom extends outboard of the frame. The fairlead is supported uponthe frame at a fairlead mounting location that is longitudinally betweenthe front frame end and the back frame end and latitudinally between thesideboom and the winch assembly. The fairlead is pivotable about afairlead pivot axis so as to position the fairlead at a range oforientations for feeding a hoisting cable between the winch assembly andthe sideboom.

In still another aspect, a fairlead for a ground-engaging machineincludes a fairlead base structured for coupling to a frame of theground-engaging machine. The fairlead further includes a fairlead boomhaving a first boom end and a second boom end, and a through-channelextending between an inboard boom side and an outboard boom side at alocation between the first boom end and the second boom end. Thefairlead further includes a pivot joint pivotably coupling the fairleadboom to the fairlead base and defining a fairlead pivot axis. Thefairlead further includes a first feed pulley and a second feed pulleyeach mounted to the fairlead boom and positioned at least partiallywithin the through-channel, and being arranged so as to feed a hoistingcable passed between the first feed pulley and the second feed pulleybetween a winch assembly and a sideboom in the machine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of a machine, according to one embodiment;

FIG. 2 is a block diagram of a control system suitable for use in themachine of FIG. 1;

FIG. 3 is a diagrammatic view of parts of a hoisting system, accordingto one embodiment;

FIG. 4 is a flowchart illustrating example process and control logicflow, according to one embodiment; and

FIG. 5 is a partially open side diagrammatic view of a pivoting fairleadshown as it might appear ready for installation on a centerframe beam ofa machine, according to one embodiment.

DETAILED DESCRIPTION

Referring to FIG. 1, there is shown a ground-engaging machine 10according to one embodiment, and structured as a pipelayer machine fortransporting, suspending, and placing pipe sections of a pipelineaccording to generally known practices. Machine 10 includes a frame 12having a front frame end 16 and a back frame end 18. An engine system 14is mounted adjacent to front frame end 16 in the illustrated embodiment.An operator station 22 is coupled to and mounted upon frame 12 betweenfront frame end 16 and back frame end 18. Operator station 22 caninclude an operator cab. Ground-engaging elements 20, including tracksin the illustrated embodiment, are coupled to and positioned uponopposite sides of frame 12. Machine 10 further includes a counterweight24 positioned upon one side of frame 12 and adjustable by way of one ormore counterweight actuators 26 in a generally conventional manner.

Machine 10 also includes a hoisting system 28 having a sideboom 30movable by pivoting relative to frame 12 about a sideboom pivot axis 32.Sideboom 30 may be pivotable between a raised or stowed position, atwhich sideboom 30 may be generally aligned with a vertical line 33, anda second sideboom position at which sideboom 30 extends outboard offrame 12. The second sideboom position could be approximately asillustrated in FIG. 1, however, sideboom 30 may be structured forlowering further than what is shown in FIG. 1, below a horizontal planein certain embodiments. An example sideboom pivoting range is shown at100. Those skilled in the art will be familiar with positioning andadjustment of a counterweight such as counterweight 24 to offset a loadsupported by way of sideboom 30, such as a length of pipe. In animplementation, sideboom 30 may be coupled to frame 12 at each of aforward-mounting location and a rearward-mounting location by way of aforward connector 34 and a rearward connector 36. Sideboom 30 mayfurther include a first or forward beam 38 and a second or rearward beam40 that extend from connectors 34 and 36 in a generally triangularpattern. Other sideboom designs and configurations could be employed indifferent embodiments.

Hoisting system 28 further includes an upper hook pulley block 42supported by sideboom 30, and a hoisting cable 66. A lower hook pulleyblock 44 is suspended by way of hoisting cable 66 from upper hook pulleyblock 42 and includes a hook 46 for suspending a load, such as a pipesection within a roller sling or the like. One or more boom cables 48extend between sideboom 30 and a winch assembly or system 50. Winchsystem 50 can include a first winch 52 including a winding drum or thelike not visible in FIG. 1, and a second winch 54 including a secondwinding drum or the like also not visible in FIG. 1. Hoisting cable 66may be attached to and wound about the drum of second winch 54, whereasone or more of cables 48 can be attached to and wound about the drum offirst winch 52.

Hoisting system 28 also includes a fairlead 56 movable by pivotingrelative to frame 12 about a fairlead pivot axis 64. Sideboom pivot axis32 and fairlead pivot axis 64 have fixed orientations relative to frame12 and extend in parallel with one another in a fore-to-aft direction.Fairlead 56 can include a fairlead base 58 and a fairlead boom 60supported upon fairlead base 58. Fairlead base 58 may be supported uponand coupled to frame 12 at a third location, or fairlead mountinglocation, that is longitudinally between front frame end 16 and backframe end 18, and latitudinally between sideboom 30 and winch system 50.The fairlead mounting location can also be vertically higher than andinboard of the forward location of connector 34 and the rearwardlocation of connector 36, and between the forward location and therearward location in a longitudinal or fore-to-aft direction. Thefairlead mounting location can also be forward of operator station 22,and outboard of operator station 22. Fairlead 56 may be mounted, such asby bolting or welding, to a centerframe beam 55, or to frame 12directly. Fairlead 56 may also include a cable guide 62 in the nature ofa bar having upturned ends to form, generally, a U-shape, for receivingand locating boom cables 48 when sideboom 30 is lowered. Hoisting cable66 extends through each of fairlead 56 and upper hook pulley block 42.The weight of hook pulley block 44, as well as any load also suspendedby hook 46, holds hoisting cable 66 in tension such that hoisting cable66 couples the pivoting of fairlead 56 to the pivoting of sideboom 30.Fairlead 56 might be pivoted about pivot axis 64 from the orientationshown in FIG. 1 to a raised or stowed position aligned with a verticalline 65, or to a lowered position. Pivoting of fairlead 56 positionsfairlead 56 at any of a range of orientations, relative to frame 12 andto an underlying substrate, for feeding hoisting cable 66 between winchsystem 50 and sideboom 30. Pivoting of fairlead 56 defines a fairleadpivot range 110. Pivoting of sideboom 30 defines sideboom pivot range100 as noted above. Fairlead pivot range 110 may be smaller than pivotrange 100. Pivoting of fairlead 56, and in particular lowering offairlead 56 as sideboom 30 is lowered to place a pipe section in atrench, can improve an operator or ground crew field of view, and inparticular operator line of sight to hook 46, from what would typicallybe observed where a traditional, non-pivoting fairlead is used. Anoperator field of view from operator station 22 to an underlyingsubstrate, such as a left-forward quadrant of an operator field of view,may thus be obstructed to a relatively greater extent when fairlead 56is raised, and to a relatively lesser extent when fairlead 56 islowered. It can therefore be appreciated that as sideboom 30 is lowered,potential obstruction of the field of view by fairlead 56 can bereduced, a feature contemplated to provide advantages during operatingmachine 10.

Hoisting system 28 further includes a control system 70. Control system70 includes a fairlead sensor 72 structured to produce a fairleadmonitoring signal indicative of an orientation of fairlead 56. Controlsystem 70 further includes a load sensor 74 structured to produce a loadmonitoring signal indicative of a load on hoisting cable 66. In oneembodiment each of fairlead sensor 72 and load sensor 74 is resident onfairlead 56. Control system 70 also includes a cable feed sensor 76structured to produce a cable feeding signal indicative of a length ofhoisting cable 66 fed through fairlead 56. Cable feed sensor 76 may alsobe resident on fairlead 56. A counterweight sensor 78 is associated withcounterweight 24 and structured to produce a counterweight monitoringsignal indicative of an orientation of counterweight 24 relative toframe 12. It should be appreciated that a position of any one of thepivotable components of interest discussed herein can be indicative ofan orientation, and vice versa such that the terms position andorientation are used interchangeably. Accordingly, rotarypotentiometers, linear potentiometers, Hall effect sensors, inductivesensors, capacitive sensors, mechanical switches, and still others canbe employed to directly, indirectly, or inferentially indicate relativepositions and orientations of components of machine 10, the significanceof which will be further apparent from the following description. Aframe sensor is shown at 98 and produces a frame monitoring signalindicative of an orientation of frame 12 relative to an underlyingsubstrate. Sensors 72, 74, and 76 may be part of instrumentationcircuitry, further discussed herein and shown at reference numeral 71 inFIG. 3, that is part of and resident on fairlead 56. Sensor 78, andpotentially other sensors, may be part of hoisting control circuitry,also further discussed herein and shown at reference numeral 79 in FIG.3, that is onboard machine 10. Hoisting control circuitry 79 can alsoinclude or be coupled with one or more computers and operator input andcontrol devices, as explained below. A wiring harness 96 may be part ofinstrumentation circuitry 71 and structured to electrically connectinstrumentation circuitry 71 to hoisting control circuitry 79, asfurther discussed herein.

Referring also now to FIG. 2, there are shown components of controlsystem 70 in an example arrangement. Control system 70 also includes anelectronic control unit 80 having an input/output interface 84, forreceiving inputs from various sensors and sending outputs in the natureof control commands, monitored quantities or qualities, and conditionalerts as further discussed herein. Electronic control unit 80 furtherincludes a processor 82, which can include any suitable centralprocessing unit such as a microcontroller or a microprocessor. Processor82 is in communication with a memory 86 that stores computer executableprogram instructions in the nature of a load monitoring program orcontrol routine 88 and a cable feed program or control routine 90, asalso further discussed herein. Memory 86 can include RAM, ROM, a harddrive, Flash, SDRAM, EEPROM, or still another type of memory. A loadcurve map is shown at 92 and is referenced by load monitoring routine 88to determine a load condition of machine 10, such as an overloadcondition or likely overload condition, and generate appropriate alerts,as further discussed herein. A display 94, which may be mounted in or onoperator station 22, can include a graphical user interface such as atouchscreen (not numbered), structured to convey various types ofinformation to an operator, and receive control inputs from an operator.A plurality of icons are shown at 95 and represent alerts or warningsthat can be presented to an operator by way of illumination, forexample. Other operator perceptible alerts such as audible alerts mightbe used.

In a practical implementation strategy, some or all of the components ofcontrol system 70 can be provided on or in fairlead 56. As noted above,each of sensors 72, 74, and 76 can be resident on fairlead 56, inparticular resident on fairlead boom 60. Frame sensor 98 may be residenton fairlead base 58. Wiring harness 96 extends between fairlead 56 andelectronic control unit 80, which can include a machine control unitstructured for monitoring and controlling various aspects and functionsof machine 10, or a dedicated electronic control unit for controllingand/or monitoring hoisting system 28. As also noted above, certain knownpipelayers include non-pivoting fairleads. It is contemplated thatfairlead 56 can be swapped for existing fairleads on pipelayers alreadyin the field. In this general manner, some or all of the instrumentationfor a hoisting system can be provided onboard an aftermarket fairleadinstalled in place of an existing fairlead. Certain earlier attempts atsideboom monitoring provided instrumentation on or associated with apipelayer sideboom. A sideboom of a pipelayer is often removed fortransport, requiring electrical connections for sideboom sensors and thelike to be broken and reestablished, if at all, when a sideboom isremoved and then reinstalled for use at another worksite. A hoistingsystem including a fairlead according to the present disclosure hasinstrumentation that can remain onboard, and connections that are notdisrupted by way of usual disassembly of the pipelayer machine fortransport or servicing.

Referring also now to FIG. 3, there is shown a view of parts of hoistingsystem 28 in further detail, and showing fairlead base 58 as it mightappear installed upon and mounted to frame 12 (or centerframe beam 55)by way of a plurality of bolts 99. Instrumentation circuitry 71 isresident on fairlead 56. Wiring harness 96 and/or an associated plug(not numbered) can electrically connect instrumentation circuitry tohoisting control circuitry 79. It should be appreciated that the termcircuitry as used herein contemplates not only electrical wiring and thelike but also circuit elements and electrical components such assensors, plugs, switches, capacitors, inductors, filters, transistors,and still others. Accordingly, wiring alone is not fairly consideredinstrumentation circuitry or control circuitry in the present context.In one embodiment, fairlead 56 can be installed in place of an existingfairlead and exploit the same bolting pattern that was used for theexisting fairlead. Also shown in phantom in FIG. 3 is fairlead 56, andin particular boom 60 as it might appear raised and lowered. Hoistingcable 66 can be seen to extend through fairlead 56, in contact with andbetween a plurality of feed pulleys including a first feed pulley 61 anda second feed pulley 63 that guide hoisting cable 66 through fairlead56. It will be recalled that load sensor 74 may be resident on fairlead56, and in a practical implementation strategy includes a strain gaugecoupled with a pulley pin 77 of first feed pulley 61. A force vector 120is depicted in FIG. 3, and represents an example force exerted bytensioned hoisting cable 66 on first feed pulley 61. The contact betweenhoisting cable 66 and first feed pulley 61, and strain on pulley pin 77enables load sensor 74 to produce the load monitoring signal that isindicative of a load on hoisting cable 66. Because the load or tensionon hoisting cable 66 can vary with an orientation of fairlead 56,electronic control unit 80 can be structured to determine the actualcurrent load or hook load based upon both the observed load on hoistingcable 66 as indicated by the raw load monitoring signal, and theorientation of fairlead 56, in turn indicative of an orientation ofsideboom 30 that is suspending the hook load. As an alternative to astrain gauge, a different type of load sensor might be used such as aposition sensor coupled with a displaceable mechanism such as a gasspring, a mechanical spring, or an otherwise deformable or deflectablemechanism.

It will also be recalled that cable feed sensor 76 produces a cablefeeding signal indicative of a length of hoisting cable 66 fed throughfairlead 56. In one embodiment cable feed sensor 76 can be structured tooutput the cable feeding signal each time feed pulley 63 completes arotation in a first direction. Sensor 76, or another sensor (not shown),could output a cable infeed signal each time pulley 63 completes arotation in an opposite direction. Still other strategies could be used,such as an arrangement of sensor targets on pulley 63 that are sensed toindicate rotation in one direction by way of a first pattern rotatedpast a sensor and indicate rotation in an opposite direction by way of areverse pattern rotated past the sensor. Those skilled in the art willbe familiar with the phenomenon of pulley block collision, and itspotential risks of straining a hoisting cable or causing other problems.Electronic control unit 80 may be structured to output a pulley blockcollision alert based on the cable feeding signal. The pulley blockcollision alert can be based also upon the orientation of fairlead 56,since a length of cable fed through fairlead 56 can vary based uponvarying orientation of fairlead 56. In other words, with fairlead 56raised versus lowered different lengths of fed-out or fed-in cable willbe associated with pulley block collision risk. A location of thenormally stationary upper hook block 42 in space can be determined onthe basis of fixed boom geometry and boom angle, which is directlyproportional to fairlead angle/orientation. A location of lower hookblock 44 can be determined on the basis of a length of cable fed throughfairlead 56, with a number of pulley revolutions in a feeding outdirection being proportional to cable length. Also shown in FIG. 3 is asensor 81 that can be used in place of fairlead sensor 72 or as asupplement to fairlead sensor 72. Sensor 81 could be a rotary sensorstructured to produce the fairlead monitoring signal responsive to anangular orientation of fairlead 56 about fairlead pivot axis 64. Each offairlead sensor 72 and frame sensor 98 can include an inertialmeasurement unit or IMU in some embodiments. Electronic control unit 80can receive the fairlead monitoring signal from fairlead sensor 72 (orfrom sensor 81), and the frame monitoring signal from sensor 98, todetermine an orientation of fairlead 56, and based upon the knownrelationship between fairlead orientation and sideboom orientation,determine an angle of sideboom 30 relative to a horizontal referenceplane or some other reference. In this general manner, electroniccontrol unit 80 monitors orientation of fairlead 56 and can account forpositioning of machine 10 upon a slope, and thus determine whether thereis a risk of tipping over of machine 10 when supporting a given load. Ifit is determined, based on the fairlead monitoring signal and the loadmonitoring signal, that an unacceptable risk of tipping exists, or foranother reason machine stability is compromised or likely to becompromised, electronic control unit 80 can output an overload alert toindicate to an operator that a limit has been reached or that correctiveaction needs to be taken, as further discussed herein.

Referring to FIG. 5, there is shown a fairlead 156 which may be similarto or identical to the fairlead embodiments discussed above, andillustrating further details and features thereof. It will thus beappreciated that the following description of the embodiment of FIG. 5can be understood by way of analogy to refer to other embodimentsexplicitly described and otherwise contemplated herein, and vice versa.Fairlead 156 is shown as it might appear in the process of beinginstalled on a centerframe beam 155. Centerframe beam 155 can be part ofa machine frame or structured for mounting upon a machine frame such asmachine frame 12 discussed above. Fairlead 156 could also be installedon a different frame subcomponent, or directly to a main machine frameitself. In the illustrated embodiment, fairlead 156 includes a fairleadbase 158 that includes a post 182. Post 182 can be integral withfairlead base 158 or attached to fairlead base 158 by bolting orwelding, for example. Post 182 can include a plurality of bolting holes184 formed therein, and is shown as it might appear being inserted intoa complementarily shaped aperture 185 in centerframe beam 155. Loweringof fairlead 156 such that post 182 drops further into aperture 185 canalign bolting holes 184 with bolting holes 186 formed in centerframebeam 155 itself. A plurality of bolts 188 are shown that can beinstalled through bolting holes 186 for threaded engagement in boltingholes 184. It will be recalled that bolting holes and bolts can be usedto mount other embodiments. For instance, in the embodiment of FIG. 3fairlead 56 is bolted by way of bolts 99 that are generally orientedvertically and thus parallel to a longitudinal axis of the fairlead whenoriented at a raised fairlead position. Bolting holes 184, 186, andbolts 188 can be horizontally installed, in contrast. It should also beappreciated that other mounting strategies, including welding, could beemployed within the present context. It is contemplated that fairleadsmight be welded in place in newly manufactured machines, and bolted wheninstalled to existing machines already in the field. The presentdisclosure is not limited to any particular mounting strategy for afairlead.

Fairlead boom 160 includes a first boom end 171 and a second boom end173. A through-channel 175 extends between an inboard boom side 176 andan outboard boom side 177 at a location between first boom end 171 andsecond boom end 173. A pivot joint 180 pivotably couples fairlead boom160 to fairlead base 158 and defines a fairlead pivot axis 164. A firstfeed pulley 161 defines a first feed pulley axis 165, and a second feedpulley 163 defines a second feed pulley axis 167. Each of first feedpulley 161 and second feed pulley 163 is mounted to fairlead boom 160and positioned at least partially within through-channel 175. First feedpulley 161 and second feed pulley 163 are arranged so as to feed ahoisting cable 166, analogous to the other embodiments contemplatedherein, passed in a serpentine path between first feed pulley 161 andsecond feed pulley 163 between a winch assembly and a sideboom in theassociated ground-engaging machine. Fairlead boom 160 defines a fairleadlongitudinal axis 169 extending between first boom end 171 and secondboom end 173. Fairlead boom 160 includes a first side plate 179 and asecond side plate 181 extending continuously between first boom end 171and second boom end 173. Through-channel 175 is formed by first sideplate 179 and second side plate 181, with each of first feed pulley 161and second feed pulley 163 being supported between first side plate 179and second side plate 181. In one implementation, fairlead 156 can havea bend or curvature of side plates 179 and 181 such that outboard boomside 177 has a concave profile adjacent to pivot joint 180, and a convexprofile adjacent to second boom end 173.

INDUSTRIAL APPLICABILITY

Referring to the drawings generally, but in particular now to FIG. 4,there is shown a flowchart 200 illustrating example process and controllogic flow corresponding to load monitoring program 88, and exampleprocess and control logic flow corresponding to cable feed program 90.It should be appreciated that programs 88 and 90 could be executed assubroutines of the same software program or could run as separateparallel routines. References in the following description to one of theembodiments herein should be understood to refer by way of analogy toany of the other embodiments contemplated herein. At a block 205 isshown the body IMU (frame sensor 98) that produces the frame monitoringsignal, and at a block 210 is shown a fairlead boom IMU (fairlead sensor72) that produces the fairlead monitoring signal. An angle converter isshown at a block 220 whereby electronic control unit 80 calculates anangle of sideboom 30 relative to a reference such as a horizontalreference plane. It will be recalled fairlead orientation is directlyproportional to sideboom orientation. The specific proportionalrelationship will depend upon relative lengths and positioning offairlead 56 and sideboom 30. At a block 225 a boom overhang calculatoris shown, which can enable electronic control unit 80 to determine therelative extent to which, or the absolute extent to which, sideboom 30extends outwardly of frame 12. At a block 230 is shown counterweightIMU, which can monitor a counterweight position to produce a monitoringsignal by way of sensor 78, for example. At a block 231 a positionconverter converts a position signal indicative of counterweightposition to a counterweight angle, for example. A max load calculator isshown at 232. At block 232, electronic control unit 80 can determine amax allowable load for a given orientation of fairlead 56, at a givenorientation of machine 10/frame 12, and at a given orientation ofcounterweight 24. As further discussed below, electronic control unit 80can output the overload alert based on a current hook load and thedetermined max allowable load from block 232.

It should also be appreciated that changing a sideboom angle, forinstance, can change the max allowable load and justify outputting anoverload alert. For example, an operator might lower sideboom 30 from afirst orientation where a given hook load is allowable to a secondorientation where the given hook load is not allowable. In suchcircumstances an overload alert can be output and the operator, orcontrol system 70, could raise sideboom 30, raise counterweight 24,adjust both sideboom 30 and counterweight 24, or take some other action.Machine underfoot conditions could also be a factor in what maxallowable loads or other threshold conditions are determined and howthose conditions are managed. In view of the foregoing, it will thus beappreciated that load monitoring and management of overload and othermachine operating conditions according to the present disclosure can bea dynamic process.

At a block 235 is shown the strain pin, producing the load monitoringsignal by way of sensor 74. At a block 240 is depicted a strain to loadconverter where a strain detected by way of sensor 74 is converted to aload on hoisting cable 66. The determined load on hoisting cable 66 canbe converted to a current hook load according to known trigonometric orother computational or inferential techniques, for example. A load curvemap is shown at a block 245. At block 245 electronic control unit 80 cancompare the max allowable load to a current hook load. The load curvemap might include a current hook load coordinate and a max loadcoordinate. An alternative strategy could include a cable loadcoordinate, a fairlead boom angle coordinate, a max load coordinate,and/or a counterweight angle coordinate. Still other map configurationscould be used.

Several of the blocks in control routine 88 represent information thatcan be displayed on display 94 to an operator. Machine angle is shown ata block 250 and can represent machine angle as determined on the basisof data from frame sensor 98. Boom angle is shown at a block 255 and candisplay to an operator an angle of sideboom 30 relative to a horizontalreference plane, or relative to some other reference such as frame 12.At a block 260, boom overhang is displayed. At a block 262, the max loaddetermined at max load calculator 232 is displayed. At a block 265, thecurrent hook load on hoisting cable 66 is displayed. Block 270 displaysa percent load, meaning a percent of max allowable load that iscurrently applied to a hoisting cable 66. At a block 272 counterweightposition is displayed.

At a block 280 of program 90 is shown cable feed or the cable feedingsignal produced by cable feed sensor 76. At a block 282 is shown afeed-to-cable length converter where, for example, a number of pulleyrotations is converted to a cable length. At a block 288, it is queriedwhether conditions are near the 2-block limit, based on determinedlocations of hook blocks 42 and 44 as described herein. If no, thecontrol routine can end or exit at a block 294. If yes, the controlroutine can advance to a block 299 to output an anti-2-block warning orpulley collision alert. At a block 286 electronic control unit 80 canreceive the load on hoisting cable 66 and query whether conditions arenear a load limit? If no, the control routine can advance to a block 292to end or exit. If yes, the control routine can advance to a block 298to produce the load warning or overload alert.

The present description is for illustrative purposes only, and shouldnot be construed to narrow the breadth of the present disclosure in anyway. Thus, those skilled in the art will appreciate that variousmodifications might be made to the presently disclosed embodimentswithout departing from the full and fair scope and spirit of the presentdisclosure. Other aspects, features and advantages will be apparent uponan examination of the attached drawings and appended claims. As usedherein, the articles “a” and “an” are intended to include one or moreitems, and may be used interchangeably with “one or more.” Where onlyone item is intended, the term “one” or similar language is used. Also,as used herein, the terms “has,” “have,” “having,” or the like areintended to be open-ended terms. Further, the phrase “based on” isintended to mean “based, at least in part, on” unless explicitly statedotherwise.

What is claimed is:
 1. A fairlead for a hoisting system in aground-engaging machine comprising: a fairlead base for coupling to aframe of the ground-engaging machine; a fairlead boom; a pivot jointpivotably coupling the fairlead boom to the fairlead base; a pluralityof feed pulleys mounted to the fairlead boom for feeding a hoistingcable through the fairlead between a winch assembly and a sideboom inthe ground-engaging machine; instrumentation circuitry including awiring harness structured for electrically connecting theinstrumentation circuitry of the fairlead to hoisting control circuitryof the hoisting system included onboard the ground-engaging machine; andwherein the instrumentation circuitry further includes a sensor residenton the fairlead boom.
 2. The fairlead of claim 1 wherein the sensor isstructured to produce a fairlead monitoring signal indicative of anorientation of the fairlead relative to the frame of the ground-engagingmachine.
 3. The fairlead of claim 2 wherein the sensor includes aninertial measurement unit (IMU).
 4. The fairlead of claim 2 wherein theinstrumentation circuitry further includes a frame sensor resident onthe fairlead base and structured to produce a frame monitoring signalindicative of an orientation of the frame of the ground-engaging machinerelative to an underlying substrate.
 5. The fairlead of claim 1 whereinthe sensor includes a load sensor structured to produce a load signalindicative of a load on the hoisting cable.
 6. The fairlead of claim 1wherein the sensor includes a cable feed sensor structured to output acable feeding signal indicative of a length of the hoisting cable fedthrough the fairlead.
 7. The fairlead of claim 1 wherein the fairleadbase includes a plurality of bolting holes formed therein for boltingthe fairlead to the frame of the ground-engaging machine.
 8. A fairleadfor a hoisting system in a ground-engaging machine comprising: afairlead base for coupling to a frame of the ground-engaging machine; afairlead boom; a pivot joint pivotably coupling the fairlead boom to thefairlead base; a plurality of feed pulleys mounted to the fairlead boomfor feeding a hoisting cable through the fairlead between a winchassembly and a sideboom in the ground-engaging machine; instrumentationcircuitry including a wiring harness structured for electricallyconnecting the instrumentation circuitry of the fairlead to hoistingcontrol circuitry of the hoisting system included onboard theground-engaging machine; and the instrumentation circuitry furtherincluding a sensor resident on the fairlead boom, wherein the sensorresident on the fairlead boom includes one or more of: a first sensorstructured to produce a fairlead monitoring signal indicative of anorientation of the fairlead relative to the frame of the ground-engagingmachine, a load sensor structured to produce a load signal indicative ofa load on the hoisting cable, and a cable feed sensor structured tooutput a cable feeding signal indicative of a length of the hoistingcable fed through the fairlead.
 9. The fairlead of claim 8 wherein theinstrumentation circuitry further includes a frame sensor resident onthe fairlead base and structured to produce a frame monitoring signalindicative of an orientation of the frame of the ground-engaging machinerelative to an underlying substrate.
 10. The fairlead of claim 9 whereinthe first sensor includes an inertial measurement unit (IMU).
 11. Thefairlead of claim 8 wherein the fairlead base includes a plurality ofbolting holes formed therein for bolting the fairlead to the frame ofthe ground-engaging machine.
 12. A fairlead for a hoisting system in aground-engaging machine comprising: a fairlead base for coupling to aframe of the ground-engaging machine; a fairlead boom; a pivot jointpivotably coupling the fairlead boom to the fairlead base; a pluralityof feed pulleys mounted to the fairlead boom for feeding a hoistingcable through the fairlead between a winch assembly and a sideboom inthe ground-engaging machine; instrumentation circuitry including awiring harness structured for electrically connecting theinstrumentation circuitry of the fairlead to hoisting control circuitryof the hoisting system included onboard the ground-engaging machine;wherein the instrumentation circuitry further includes a first sensorresident on the fairlead boom and a frame sensor resident on thefairlead base, the frame sensor structured to produce a frame monitoringsignal indicative of an orientation of the frame of the ground-engagingmachine relative to an underlying substrate.
 13. The fairlead of claim12 wherein the instrumentation circuitry further includes a load sensorstructured to produce a load signal indicative of a load on the hoistingcable.
 14. The fairlead of claim 13 wherein the instrumentationcircuitry further includes a cable feed sensor structured to output acable feeding signal indicative of a length of the hoisting cable fedthrough the fairlead.
 15. The fairlead of claim 14 wherein the firstsensor includes an inertial measurement unit (IMU) and is structured toproduce a fairlead monitoring signal indicative of an orientation of thefairlead relative to the frame of the ground-engaging machine.